Modular block wall system

ABSTRACT

A modular masonry system includes a plurality of masonry modules each having inner and outer structural members. Top and bottom spanning members extend the length of the inner and outer structural members and are retained within respective upper and lower retaining grooves of the inner and outer structural members. The top spanning member includes a second retaining feature that cooperates with a first retaining feature of the bottom spanning member of an adjacent masonry module. An insulation member is disposed within an interior volume defined between the inner and outer structural members and the top and bottom spanning members. The first retaining feature of each bottom spanning member slidably engages the second retaining feature of at least one vertically adjacent top spanning member. The engagement of the first and second retaining features aligns and secures the engaged masonry modules without the use of mortar.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.14/588,724 filed Jan. 2, 2015, entitled MODULAR BLOCK WALL SYSTEM, theentire disclosure of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to block-type buildingmaterials, and more specifically, a modular block and a modular blockwall system that does not necessarily require the use of mortar.

BACKGROUND OF THE INVENTION

Buildings and other structures are commonly built with masonry unitsthat are stacked upon one another to provide a structural foundationupon which various other aspects of the building can be attached andsupported. These masonry walls typically include a modular system ofgenerally concrete or earthen modular units that are stacked in apredefined pattern and typically held together with mortar or anothercement-based material.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a block module for amodular block system includes inner and outer structural members,wherein each of the inner and outer structural members includes upperand lower retaining grooves. A bottom spanning member extends a lengthof the inner and outer structural members, wherein the bottom spanningmember is configured to be retained within the lower retaining groovesof the inner and outer structural members, and wherein the bottomspanning member includes a first retaining feature. A top spanningmember extends the length of the inner and outer structural members,wherein the top spanning member is configured to be retained within theupper retaining grooves of the inner and outer structural members, andwherein the top spanning member includes a second retaining feature thatis configured to cooperate with the first retaining feature of anadjacent block module. An insulation member is disposed within aninterior volume defined between the inner and outer structural membersand the top and bottom spanning members, wherein the insulation memberis compressed between the inner and outer structural members, andwherein the top and bottom spanning members engage the upper and lowerretaining grooves to exert a laterally inward compressive force againstthe inner and outer structural members to compress the insulation memberbetween the inner and outer structural members and secure the inner andouter structural members, the top and bottom spanning members and theinsulation member in a unitary member.

According to another aspect of the present invention, a modular blocksystem includes a plurality of block modules. Each of these blockmodules includes inner and outer structural members including upper andlower retaining grooves. A bottom spanning member is included thatextends the length of the inner and outer structural members, and isconfigured to be retained within the lower retaining grooves of theinner and outer structural members. The bottom spanning member alsoincludes a first retaining feature. A top spanning member extends thelength of the inner and outer structural members and is configured to beretained within the upper retaining grooves of the inner and outerstructural members. The top spanning member includes a second retainingfeature that cooperates with the first retaining feature of an adjacentmasonry module. An insulation member is disposed within an interiorvolume defined between the inner and outer structural members and thetop and bottom spanning members. The first retaining feature of eachbottom spanning member of the plurality of masonry modules is adapted toslidably engage the second retaining feature of at least one verticallyadjacent top spanning member of the plurality of block modules such thatthe engagement of the first and second retaining features serves tolaterally and vertically align and secure the plurality of block modulesthat are so slidably engaged. When assembled, the plurality of blockmodules are aligned and secured to form a structural unit that is freeof the use of mortar.

According to another aspect of the present invention, a modular blocksystem includes a plurality of block modules each including a topspanning panel including first and second securing members extendingfrom opposite edges of the bottom spanning panel and a bottom spanningpanel including third and fourth securing members extending toward thefirst and second securing members and a first retaining feature definedwithin the opposite edges of the top spanning panel. An inner structuralmember extends perpendicularly between one of the first and secondsecuring members and one of the third and fourth securing members. Anouter structural member extends perpendicularly between the other of thefirst and second securing members to the other of the third and fourthsecuring members and the top and bottom spanning panels extendsubstantially the length of the inner and outer structural members tospace the inner and outer structural members at a predetermineddistance. The inner and outer structural members and the top and bottomspanning members define an interior volume therein. An insulation memberis disposed within the interior volume, wherein the inner and outerstructural members extend between one of the top and bottom spanningmembers. The first retaining feature of the bottom spanning panel of oneof a first block module of the plurality of block modules is adapted toslidably engage the opposite edges of the top spanning panel of at leastone vertically adjacent block modules of the plurality of block modules.The slidable engagement between the first block module and the at leastone vertically adjacent block module secures and vertically andlaterally aligns the first and the at least one vertically adjacentblock modules free of the use of mortar, wherein the first block moduleis unable to slidably engage two block modules of the at least onevertically adjacent block module when the two block modules are free ofat least one of vertical and lateral alignment.

According to another aspect of the present invention, a method forassembling a mortar free modular block system includes providing aplurality of block modules, each including inner and outer structuralmembers including upper and lower retaining grooves. A bottom spanningmember extends the length of the inner and outer structural members andis configured to be retained within the lower retaining grooves of theinner and outer structural members. The bottom spanning member includesa first retaining feature. A top spanning member extends the length ofthe inner and outer structural members and is configured to be retainedwithin the upper retaining grooves of the inner and outer structuralmembers. The top spanning member includes a second retaining featurethat cooperates with the first retaining feature of an adjacent blockmodule. An insulation member is disposed within an interior volumedefined between the inner and outer structural members and the top andbottom spanning members. At least two adjacent block modules are placedto define a lower course and are vertically and laterally aligned withinthe lower course. A vertically adjacent block module is slid onto the atleast two adjacent block modules within the lower course such that thevertically adjacent block module defines an upper course. The firstretaining feature of the vertically adjacent block module slidablyengages the second retaining feature of two of the at least two blockmodules, and a slidable connection between the at least two blockmodules of the lower course and the vertically adjacent block module ofthe upper course creates a secure and self-leveling interferenceconnection that is substantially free of mortar.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a side elevational view of a partially constructed blockmodule wall using an embodiment of the block system;

FIG. 2 is a cross-sectional view of the block module wall of FIG. 1taken along line II-II;

FIG. 3 is an enlarged cross-sectional view of the block module wall ofFIG. 2 taken at area III;

FIG. 4 is an exploded perspective view of one unit of an embodiment ofthe block system;

FIG. 5 is a cross-sectional view of an embodiment of two interlockingblock modules of FIG. 1, taken along line V-V;

FIG. 6 is a perspective view of inner and outer structural members ofanother embodiment of the block system;

FIG. 7 is an end elevational view of one of the structural members ofFIG. 6;

FIG. 8 is an enlarged perspective view of the bottom spanning panel ofanother aspect of the block module of FIG. 5;

FIG. 9 is a detail perspective view of an embodiment of the top spanningpanel of the mortarless block module of FIG. 8;

FIG. 10 is a detail cross-sectional view of the engagement between thetop and bottom spanning panels of the block system of FIG. 5;

FIG. 11 is a detail perspective view of an alternate embodiment of themodular block system showing a connecting joint between two blockmodules;

FIG. 12 is a partially exploded perspective view of the corner adapterremoved from two engaged block modules;

FIG. 13 is a perspective view of a corner adapter for an embodiment ofthe modular block system;

FIG. 14 is a second perspective view of the corner adapter of FIG. 13;

FIG. 15 is a lateral cross-sectional view of an alternate embodiment ofthe modular block system taken through a corner condition;

FIG. 16 is a bottom perspective view of one embodiment of a flangereceiver for a corner condition of the modular block system;

FIG. 17 is a perspective view of an alternate corner adapter for usewith the flange receiver of FIG. 16;

FIG. 18 is a top plan view of the corner adapter of FIG. 17;

FIG. 19 is a top perspective view of a corner block for use in a cornercondition of at least one embodiment of the modular block system;

FIG. 20 is a top plan view an assembled corner condition of a block wallusing an embodiment of the modular block wall system;

FIG. 21 is a partially exploded perspective view of the corner conditionof FIG. 20; and

FIG. 22 is a schematic flow diagram illustrating a method forconstructing a wall using an embodiment of the block system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the invention as oriented in FIG. 1. However, itis to be understood that the invention may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

As shown in FIGS. 1-12, reference numeral 10 generally refers to amortarless modular block system for use in assembling structural andnon-structural walls used to construct standalone barriers, buildingenclosures and interior walls, and other types of structures, accordingto one embodiment. The mortarless modular block system 10 includes aplurality of block modules 12. Each of the plurality of block modules 12includes inner and outer structural members 14, 16, each having upperand lower retaining grooves 18, 20. A bottom spanning member 22 of theblock module 12 extends the length of the inner and outer structuralmembers 14, 16, such that the bottom spanning member 22 is configured tobe retained within the lower retaining grooves 20 of the inner and outerstructural members 14, 16. The bottom spanning member 22 also includes afirst retaining feature 24. Each of the block modules 12 also includes atop spanning member 26 that extends the length of the inner and outerstructural members 14, 16 and is configured to be retained within theupper retaining grooves 18 of the inner and outer structural members 14,16. The top spanning member 26 includes a second retaining feature 28that is adapted to cooperate with a first retaining feature 24 of anadjacent block module 12. The block module 12 also includes aninsulation member 30 that is disposed within an interior volume definedbetween the inner and outer structural members 14, 16 and the top andbottom spanning members 26, 22. The first retaining feature 24 of eachof the bottom spanning members 22 of the plurality of block modules 12is adapted to slidably engage the second retaining feature 28 of atleast one vertically adjacent top spanning member 26 of the plurality ofblock modules 12 such that the engagement of the first and secondretaining features 24, 28 serves to laterally and vertically align andsecure the plurality of block modules 12 that are so slidably engaged.When aligned in this manner, the plurality of block modules 12 aresubstantially secured or structurally secure so as to be free of the useof mortar, or substantially free of the use of mortar.

Referring again to FIGS. 1-11, each of the upper and lower retaininggrooves 18, 20 of each block module 12 includes an expanded innerportion 40 defined within each of the inner and outer structural members14, 16. The expanded inner portion 40 extends the length of eachrespective inner and outer structural member 14, 16. In this manner,each expanded inner portion 40 is accessible through a securing aperture42 disposed at an end of the expanded inner portion 40. Accordingly,each securing aperture 42 is defined within an end wall 44 of respectiveinner and outer structural members 14, 16. Additionally, the topspanning member 26 of each block module 12 includes a first pair ofsecuring members 46 that are configured to be secured within theexpanded inner portions 40 of the upper retaining grooves 18 of theinner and outer structural members 14, 16, respectively. Similarly, thebottom spanning member 22 of each block module 12 includes a second pairof securing members 48 that are configured to be secured within theexpanded inner portions 40 of the lower retaining grooves 20 of theinner and outer structural members 14, 16. Accordingly, the first andsecond pairs of securing members 46, 48, when engaged with the upper andlower retaining grooves 18, 20 of the inner and outer structural members14, 16, are configured to position the inner and outer structuralmembers 14, 16 at a predetermined distance from one another.

According to various embodiments, the block module 12 can include aninner structural member 14 that is substantially thicker than the outerstructural member 16 or vice versa. In such an embodiment, the innerstructural member 14 of the block module 12 is the primary structuralmember of the block module 12. The inner structural member 14 can bewide enough to serve as the load-bearing member of each block module 12to carry the various loads placed upon the mortarless modular blocksystem 10 as a whole. The outer structural member 16, being thinner,serves primarily as a decorative or aesthetic element of the blockmodule 12. The outer structural member 16 can also serve as a weatherbarrier for each block module 12 and the modular block system 10. Theouter structural member 16 may carry some of the load placed upon themortarless modular block system 10. According to various embodiments,the inner structural member 14 is made of some structural material,including, but not limited to, cement, masonry, wood, metal, plastic,composite, polymer, ceramic, combinations thereof, and other structuralmaterials. The outer structural member 16 can be made of variousstructural or non-structural materials that include, but are not limitedto, wood, ceramic, masonry, concrete, plastic, glass, metal, polymers,stucco, combinations thereof, and others.

In the various embodiments, the expanded inner portion 40 of each of theinner and outer structural members 14, 16 is typically shaped to receivethe first and second pairs of securing members 46, 48 that extend fromthe top and bottom spanning members 26, 22, respectively. As such, eachof the expanded inner portions 40 and the first and second pairs ofsecuring members 46, 48 generally have a similar cross-sectional shape.This cross-sectional shape can be any one of multiple shapes which caninclude, but are not limited to, circular, rectangular, diamond-shaped,arcuate, polygonal, irregular, combinations thereof, or other similarshape that will allow first and second pairs of securing members 46, 48to be substantially secured within the expanded inner portions 40 of theinner and outer structural members 14, 16. In various alternateembodiments, it is contemplated that the first and second pairs ofsecuring members 46, 48 can have a different cross-sectional shape thanthe expanded inner portions 40 of the inner and outer structural members14, 16. These shapes can be dissimilar, so long as the geometries resultin the first and second pairs of securing members 46, 48 being securedwithin the expanded inner portions 40 of the respective inner and outerstructural members 14, 16 to properly space the inner and outerstructural members 14, 16 the predetermined distance from one another.

Referring again to FIGS. 1-11, each of the first pair of securingmembers 46 can include first and second securing members 60, 62 and thesecond pair of securing members 48 can include third and fourth securingmembers 64, 66. Each of the first, second, third and fourth securingmembers 60, 62, 64, 66 can include a hollow interior portion 68 that isadapted to receive a corresponding expansion member 70. The insertion ofthe corresponding expansion member 70 into each hollow interior portion68 is configured to expand each of the first, second, third and fourthsecuring members 60, 62, 64, 66 within the corresponding expanded innerportion 40 of the upper and lower retaining grooves 18, 20. In thismanner, after the first, second, third and fourth securing members 60,62, 64, 66 have been inserted within corresponding expanded innerportions 40 of the inner and outer structural members 14, 16, theexpansion member 70 can be inserted into the hollow interior portion 68to at least partially expand each of the first, second, third and fourthsecuring members 60, 62, 64, 66 outward to further engage the expandedinner portion 40 of the inner and outer structural members 14, 16. Thisexpansion of the first and second pairs of securing members 46, 48serves to substantially fix each of the first and second pairs ofsecuring members 46, 48 to within the corresponding expanded innerportions 40 of the inner and outer structural members 14, 16.

In the various embodiments, the expansion member 70 can include asubstantially cylindrical member that can be inserted within the hollowinterior portions 68 of the first, second, third and fourth securingmembers 60, 62, 64, 66. In the various embodiments, it is contemplatedthat the expansion member 70 includes a substantially similar geometryto that of the hollow interior portion 68. In various alternateembodiments, it is contemplated that the expansion member 70 can includea geometry different than that of the hollow interior portions 68,wherein the expansion member 70 is configured to have a geometry thatefficiently slides within the hollow interior portion 68 of each of thefirst, second, third and fourth securing members 60, 62, 64, 66 and alsoefficiently expands the hollow interior portion 68 to provide asubstantially secure fit between the first, second, third and fourthsecuring members 60, 62, 64, 66 and the expanded inner portions 40 ofthe inner and outer structural members 14, 16. In various alternateembodiments, it is contemplated that the first, second, third and fourthsecuring members 60, 62, 64, 66 can be solid members with no hollowinterior portions 68. In such an embodiment, the expansion member 70 maynot be necessary.

As illustrated in the embodiments of FIGS. 1-11, each of the first,second, third and fourth securing members 60, 62, 64, 66 can alsoinclude a slot 80 that extends the length of each of the first, second,third and fourth securing members 60, 62, 64, 66. This slot 80 isadapted to foster the expansion of the hollow interior portion 68 ofeach of the first and second pairs of securing members 46, 48 when theexpansion member 70 is inserted into each hollow interior portion 68. Inthe various embodiments, the slot 80 can include a linear apertureextending the length of the first and second pairs of securing members46, 48. In various alternate embodiments, the slot 80 can includecertain geometries, such as angles, ridges, corners, and other similargeometries that can be adapted to provide an additional engaging surfaceof each of the first, second, third and fourth securing members 60, 62,64, 66 within the corresponding expanded inner portions 40 of the innerand outer structural members 14, 16.

In the various embodiments, it is contemplated that the inner and outerstructural members 14, 16 can be made of a cement-based material, suchas concrete, or other similar masonry material. In forming each of theinner and outer structural members 14, 16, the inner and outerstructural members 14, 16 can be cured within forms using a curingprocess that implements portland cement and water. Alternatively, theinner and outer structural members 14, 16 can be oven baked or ovencured to arrive at the final dimensional configuration described andshown in the various embodiments. In the various embodiments, the upperand lower retaining grooves 18, 20 and the expanded inner portions 40defined therein can be formed during the creation of each of the innerand outer structural members 14, 16. In various alternate embodiments,the upper and lower retaining grooves 18, 20 and the expanded innerportions 40 can be formed through removing material from thepre-manufactured inner and outer structural members 14, 16. In such anembodiment, the upper and lower retaining grooves 18, 20 can be definedthrough grinding, cutting and other similar material-removingoperations. It is also contemplated that the inner and outer structuralmembers 14, 16 can be made of various other materials including, but notlimited to, stone, reinforced concrete, wood, metal, plastic, ceramic,combinations thereof, and other similar materials.

It is contemplated that, in the various embodiments, the top and bottomspanning members 26, 22 can be made of various materials that caninclude, but are not limited to, plastic, metal, polymers, compositematerials, combinations thereof, and other similar rigid andsubstantially sturdy materials that can be used to link the variousblock modules 12 together. It is further contemplated that theinsulation member 30 of each of the block modules 12 can be a solidpiece or a block of insulation, a spray-foam-type insulation, insulativebatting, rolled insulation, or other similar insulating material thatcan be disposed within and substantially retained within the interiorvolume defined between the inner and outer structural members 14, 16 andthe top and bottom spanning members 26, 22. In various alternateembodiments, each masonry member can include end panels thatsubstantially contain the insulation member 30 within the interiorvolume that is further defined by the end panels of each block module12. It is contemplated that end panels can include latching orconnecting mechanisms that are configured to engage and at leastpartially retain a mating portion of an adjacent panel of a verticallyor laterally adjacent block module 12. In this manner, the end panelscan assist in locating and/or positioning the block modules 12 to formthe structural wall of the mortarless modular block system 10.

Referring again to FIGS. 4-11, the top spanning member 26 of each of theblock modules 12 can include a second retaining feature 28 that includesat least one engagement rail that is configured to engage one of theopposite sides of the bottom spanning member 22 of at least onevertically adjacent block module 12. In this manner, the secondretaining feature 28 is configured to slidably engage the verticallyadjacent bottom spanning member 22. In the various embodiments, thesecond retaining feature 28 can include opposing first and secondengagement rails 90, 92 that extend toward one another. The opposingfirst and second engagement rails 90, 92, which extend from the planarsurface 94 of the top spanning member 26, are adapted to receive thefirst retaining feature 24 of the bottom spanning member 22 of the atleast one vertically adjacent block module 12. It is contemplated thatthe first retaining feature 24 and the bottom spanning member 22 candefine a single continuous planar unit where the first retaining feature24 is co-planar with the bottom spanning member 22 and extends outwardand beyond the third and fourth securing members 64, 66 located at theopposite edges of the bottom spanning member 22. Accordingly, the firstretaining feature 24 is adapted to slide between the first and secondengagement rails 90, 92 defined within the second retaining feature 28of the top spanning member 26.

In the various embodiments, the first and second retaining features 24,28 can be switched such that the first and second engagement rails 90,92 are disposed within the bottom spanning member 22 and the topspanning member 26 includes the substantially planar surface 94 thatincorporates the first retaining feature 24. In still other alternateembodiments, each of the first and second retaining features 24, 28 caninclude one engagement rail that engages a substantially planar portiondefined within the other of the top and bottom spanning members 26, 22.It is also contemplated that each of the first and second retainingfeatures 24, 28 can include first and second engagement rails 90, 92that slidably and matingly engage one another to securely connect thevertically adjacent block modules 12. In the various embodiments, eachof the top and bottom spanning members 26, 22 can include respective topand bottom spanning panels that extends between the components of therespective second and first retaining features 28, 24.

It is contemplated that, in various embodiments, the first and secondretaining features 24, 28 may extend along only a portion of therespective bottom and top spanning members 22, 26. In such anembodiment, the first and second retaining features 24, 28 can beshorter in length than the respective bottom and top spanning members22, 26. In such an embodiment, the first and second retaining features24, 28 can be intermittently spaced. In this manner, the block modules12 can be placed upon a particular course at an internal portion of thelower course. This configuration allows the block modules 12 to beplaced on and structurally secured to the lower course without having toengage the block module at the end of the lower course and sliding theblock module 12 along potentially long stretches of the already securedlower course. Rather, this configuration allows the block module 12 tobe engaged along the interior block modules 12 of the lower course suchthat the intermittently spaced first and second retaining features 24,28 provide internal insertion points at which the block modules can beengaged with the lower course.

According to various embodiments, the first and second retainingfeatures 24, 28 can define a snapping-type connection that connects twovertically adjacent block modules 12. In such an embodiment, the firstand second retaining features 24, 28 can snap together such that thesnapping engagement positions the adjacent block modules 12 in theappropriate predetermined configuration. Additionally, the snappingengagement can incorporate the self-leveling feature such that thesnapping engagement of the first and second retaining features 24, 28can only occur when the adjacent block modules 12 are vertically andlaterally aligned with one another. It is contemplated that each of thefirst and second retaining features 24, 28 can include mating profilesthat need to be properly aligned in order to achieve the matingengagement between the first and second retaining features 24, 28. Thesnapping or mating engagement of the first and second retaining features24, 28 can also result in an interference fit that at least partiallyretains the connection between the first and second retaining features24, 28.

According to various embodiments, it is contemplated that the first andsecond retaining features 24, 28 can be installed directly into orintegrated with the inner and outer structural members 14, 16. In suchan embodiment, the bottom and top spanning members 22, 26 are not used.Accordingly, the inner and outer structural members 14, 16 are attachedto the insulation member 30 through an adhesive or some mechanicalattachment, rather than by the bottom and top spanning members 22, 26.In this embodiment, the first and second retaining features 24, 28 canbe set within the inner and outer structural members 14, 16 during theirformation, such as during curing, baking, cutting, or other formationprocess of the inner and outer structural members 14, 16. Alternatively,the first and second retaining features 24, 28 can be installed withinportions of the inner and outer structural members 14, 16 after they areformed. Such installation can be accomplished through adhesive,structural adhesive, some mechanical attachment or other similarconnection method. In this embodiment that does not utilize the bottomand/or top spanning members 22, 26, the first and second retainingfeatures are configured to engage one another in substantially the samemanner as the various embodiments described above.

In the various embodiments, the first and second engagement rails 90, 92of the first retaining feature 24 and/or the second retaining feature 28can include various geometries that can include, but are not limited to,rectangular geometries, arcuate geometries, irregular geometries,combinations thereof, and other similar geometries that allow for alaterally slidable engagement between vertically adjacent block modules12. It is further contemplated that the first retaining feature 24 caninclude opposing first and second engagement rails 90, 92 that extendtoward one another to define opposing panel reception channels 96. Insuch an embodiment, the opposing panel reception channels 96 are adaptedto receive the outer edges 98 of the bottom spanning member 22, thatdefine the second retaining feature 28 of the at least one verticallyadjacent block module 12.

In the various embodiments, where the first, second, third and fourthsecuring members 60, 62, 64, 66 include the hollow interior portion 68and are not solid, the expansion member 70 can include a substantiallycylindrical member that can be inserted within the hollow interiorportions 68 of the first, second, third and fourth securing members 60,62, 64, 66. In the various embodiments, it is contemplated that theexpansion member 70 includes a substantially similar geometry to that ofthe hollow interior portion 68. In various alternate embodiments, it iscontemplated that the expansion member 70 can include a geometrydifferent than that of the hollow interior portions 68, wherein theexpansion member 70 is configured to have a geometry that efficientlyslides within the hollow interior portion 68 of each of the first,second, third and fourth securing members 60, 62, 64, 66 and alsoefficiently expands the hollow interior portion 68 to provide asubstantially secure fit between the first, second, third and fourthsecuring members 60, 62, 64, 66 and the expanded inner portions 40 ofthe inner and outer structural members 14, 16.

According to the various embodiments, as illustrated in FIGS. 1-12, eachblock module 12 is designed to be manufactured and assembled off-site.In forming each block module 12, the insulation member 30 is formed intothe appropriate shape and dimension for fitting between the inner andouter structural members 14, 16. It is contemplated that no adhesive isused between the insulation member 30 and the inner and outer structuralmembers 14, 16, although, in various embodiments, adhesive may be used.The insulation member 30 and the inner and outer structural members 14,16 are compressed together with the insulation member 30 beingcompressed between the inner and outer structural members 14, 16. Oncecompressed, the top and bottom spanning members 26, 22 are slidablyengaged with the inner and outer structural members 14, 16. In thismanner, the first, second, third and fourth securing members 60, 62, 64,66 are slidably inserted into the respective upper and lower retaininggrooves 18, 20 to securely position the inner and outer structuralmembers 14, 16 in a compressive engagement with the insulation member30. Accordingly, the engagement of the first, second, third and fourthsecuring members 60, 62, 64, 66 with the respective upper and lowerretaining grooves 18, 20 maintains the inward compressive force exertedby the inner and outer structural members 14, 16 upon the insulationmember 30. The inward compressive force secures the components of eachblock module 12 in place to form a unitary piece that is substantiallyfree of movement between the components. In various embodiments, the endpanels of each block module 12 can serve to further secure thecomponents of the block module 12 permanently in place.

Referring now to FIGS. 1-3, in assembling the various block modules 12of the mortarless modular block system 10, the block modules 12 areplaced within various courses, or horizontal layers of block modules 12,where each higher course 110 is placed upon the previously laid lowercourse 112 that is disposed below it. In this manner, each course, whichrepresents a horizontally-extending layer of block modules 12, arestacked upon one another to form a wall system. The first course 114 canbe laid upon some foundation 116, such as a foundation wall, concreteslab, or directly upon the ground. Regardless of the foundation 116, thefirst course 114 of block modules 12 can be disposed upon a wood sillplate 108 or modular receiving plate 118 or some other sill member. Invarious embodiments, the modular receiving plate 118 can include firstand second engagement rails 90, 92 similar to that of the secondretaining feature of one of the block modules 12. The first and secondengagement rails 90, 92 can engage the first retaining feature 24 of thebottom spanning members 22 of the block modules 12 of the first course114. In an alternate embodiment, the modular receiving plate 118 caninclude a first pair of upwardly extending securing members 60 that isadapted to engage inner and outer structural members 14, 16 of one ofthe block modules 12 within the first course 114. In constructing thefirst course 114, the modular receiving plate 118 can include a sillaperture for receiving aligning members that may extend from thefoundation 116, where such aligning members can include, but are notlimited to, lag bolts, lag screws, rebar, and other similar aligningmembers. In various embodiments, the modular receiving plate 118 and/orthe block modules 12 of the first course 114 can be secured to thefoundation 116 through various attachment features that include, but arenot limited to, screws, lag screws, bolts, adhesives, combinationsthereof and other similar attachment features.

In various embodiments, in order to secure the first course 114 to thefoundation 116, the first course 114 can include a retaining compound orother similar retaining material, such as mortar, epoxy, adhesive, orother similar material, disposed between the inner and outer structuralmembers 14, 16 to substantially retain the first course 114 to thealigning member. In such an embodiment, it is contemplated that thefirst course 114 of block modules 12 can be assembled on site ratherthan preassembled off site, such as in a factory setting or otherassembly location. It is also contemplated that the bottom spanningmember 22 can be attached, adhered, or otherwise connected directly tothe foundation 116 without the use of aligning members within thefoundation 116, as described above. In such an embodiment, there may belittle need to assemble on site any of the courses of block modules 12.Alternatively, in various embodiments, mortar may be used tosubstantially secure a first course 114 of block modules 12 to the sillplate or to a foundation 116 or to aligning members of a foundation 116.In such embodiments, the insulation member 30 disposed within theinterior volume defined between the inner and outer structural members14, 16 and the bottom and top spanning members 22, 26 may be filled atleast partially with mortar to secure the block module 12 to thefoundation 116. Similar mortar-filled block modules 12 may be used tocreate lintels over windows, doors, archways, or other openings in thestructural wall.

In the various embodiments, a similar modular receiving plate 118 can beused for lintels, spanning members, or other bottom courses within amasonry wall. It is also contemplated that the mortarless modular blocksystem 10 can include a modular top plate adapted to engage upperretaining grooves 18 or the top spanning member 26 of a higher course110 of the masonry wall. Such higher courses 110 can be found at windowsills, the tops of walls or other areas where no additional courses willbe laid.

In the various embodiments, where a wood sill plate is used to supportthe first course 114 of block modules 12, a receiving plate 118 can bedirectly attached to the wood sill plate. The receiving plate 118 can besubstantially similar to the top spanning member 26 with a structuresimilar to the second retaining feature 28 included thereon. The secondretaining feature 28 of the receiving plate 118 is configured to receivethe first retaining feature 24 of the bottom spanning member 22 of eachblock module 12 of the first course 114. In the various embodiments, thereceiving plate 118 can be free of any securing members and can beattached to the wood sill plate by various features and/or adhesivesthat include, but are not limited by, bolts, screws, nails, epoxy,drying adhesive, curing adhesive, multi-part adhesive and others. In thevarious embodiments, the receiving plate 118 can include an at leastpartially solid member with the second retaining feature 28 definedtherein.

Referring again to FIGS. 1-3, after at least a portion of the firstcourse 114 is placed upon the foundation 116, or a lower course 112 islaid, the higher course 110 of block modules 12 can be slidably engagedonto the lower course 112. The bottom spanning member 22 of the highercourse 110 of block modules 12 can be slidably engaged with the topspanning member 26 of the lower course 112 of block modules 12. Inaligning the higher course 110 of block modules 12 with the lower course112 of block modules 12, the higher course 110 is generally offset withrespect to the lower course 112. In this manner, vertical seams 130 thatextend between two laterally adjacent block modules 12 extend onlythrough a single course. The misalignment of the vertical seams 130between laterally adjacent block modules 12 also serves to provide aself-leveling function of the mortarless modular block system 10, aswill be described below.

Referring again to FIGS. 1-3, when the second retaining feature 28 ofone of the block modules 12 within the lower course 112 is slidablyengaged to the first retaining feature 24 of the bottom spanning member22 of the higher course 110, the slidable engagement between the twoblock modules 12 substantially secures, structurally secures, andvertically and laterally aligns the vertically adjacent block modules 12together. This connection can be substantially free of mortar, such thatthe engagement between the first and second retaining features 24, 28properly aligns and secures each of the plurality of block modules 12.As discussed above, because the vertical joints between the laterallyadjacent block modules 12 are misaligned, a block module 12 disposed ona higher course 110 will engage two block modules 12 within the courseimmediately below. In this manner, the various block modules 12 withinthe higher course 110 can only be engaged with the two verticallyadjacent block modules 12 of the lower course 112 if the two verticallyadjacent block modules 12 are vertically and horizontally aligned withone another. In this manner, the first retaining features 24 within thehigher course 110 can slidably engage the second retaining features 28of the two laterally adjacent block modules 12 in the lower course 112.In addition, when the block modules 12 of the higher course 110 engagethe block modules 12 of the lower course 112, the various block modules12 are also leveled relative to one another such that the first andsecond retaining features 24, 28 of the block modules 12 of the lowerand higher courses 110 can slidably engage and properly align oneanother. Accordingly, if two laterally adjacent block modules 12 are outof vertical, horizontal, or level alignment, the block module 12 withinthe higher course 110 will be unable to slidably engage both of thelaterally adjacent block modules 12 within the lower course 112, untilsuch time as proper alignment is achieved. This self-levelingcharacteristic of the mortarless modular block system 10 substantiallyensures that the block modules 12 placed in higher courses 110 are inproper alignment with the block modules 12 previously laid in a lowercourse 112. The end result of the assembly of the various block modules12 of the mortarless modular block system 10 is a monolithic masonrywall that is properly aligned and structurally sound through theengagement of the various first and second retaining features 24, 28within each of the plurality of block modules 12.

Referring again to FIG. 1, it is contemplated that the size of theplurality of block modules 12 can be consistent, such that each blockmodule 12 is substantially the same size. It is contemplated that thesize of each block module 12 can be within the range of about 4″ highand about 8″ long and about 8″ deep, but can also be larger or smallerdepending upon the application and the desired aesthetic effects of thewall structure to be built. Accordingly, the mortarless modular blocksystem 10 can be adapted to create a wide variety of bond patterns thatcan include, but are not limited to, running bond, common bond, Flemishbond, Monk bond, Sussex bond, and other similar bond patterns. Invarious alternate embodiments, each block module 12 of the mortarlessmodular block system 10 can be sized similar to a cinder block forapplications requiring larger block modules 12. Each block module 12 canbe made to include an aesthetic face that is designed to be exposed.Such aesthetic face conditions can include split-face, smooth, textured,colored, various geometric or irregular patterns and/or reliefs, as wellas other aesthetic finishes.

In various embodiments, exposed portions of the top and bottom spanningmembers 26, 22 can also include finished aesthetic surfaces. By way ofexplanation and not limitation, the first and second engagement rails90, 92, which may be exposed between the horizontal joints 140 of twovertically adjacent block modules 12, can include an aesthetic finish.The finished aesthetic surface can include colors, textures, shapes,reliefs, and other aesthetic treatments.

Referring now to FIGS. 12-15, in order to produce corner conditions 178within the mortarless modular block system 10, a plurality of corneradapters 150 can be included within the mortarless modular block system10. In the various embodiments, the corner adapter 150 can include awall engagement portion 152 that is adapted to be inserted within theexpanded inner portions 40 of two vertically adjacent block modules 12.The wall engagement portion 152 is adapted to substantially fill aportion of each of the two expanded inner portions 40 and can include aspacer portion 158 that fits at least partially within the horizontaljoint 140 between the two vertically adjacent block modules 12. Invarious embodiments, the expansion members 70 can be inserted into thewall engagement portions 152 to substantially fix the corner adapter 150within the two expanded inner portions 40. The corner adapter 150 canalso include an adapter portion 154 that is adapted to receive a cornerblock 156 that slides vertically down the adapter portion 154 of thecorner adapter 150 to complete the corner between two joining wallsections that are disposed at different angles from one other. It iscontemplated that the corner section can be disposed at a right angle toaccount for the majority of masonry wall connecting points. It is alsocontemplated that the corner portion of the mortarless modular blocksystem 10 can include a variety of systems to account for acute orobtuse angles between two adjoining masonry walls.

In various embodiments, it is contemplated that two vertically adjacentcorner blocks 156 of the mortarless modular block system 10 can includelong and short extensions 170, 172 having different lengths. Inassembling the various corner blocks 156, the corner blocks 156 can beinstalled to connect with the adjoining masonry walls such that thelocations of the long and short extensions 170, 172 of the corner block156 vertically alternate such that no single vertical seam 130 extendsmore than one course through the wall constructed with the mortarlessmodular block system 10. Accordingly, each corner block 156 can includea long extension 170 and a short extension 172 set at a different anglethan the long extension 170. After a first corner block 156 is laid toadjoin two adjacent wall portions, a second corner block 156 is laidupon the first corner block 156 such that the short extension 172 restsupon the long extension 170 of the first corner block 156 and the longextension 170 of the second corner block 156 lies upon the shortextension 172 of the first corner block 156.

Referring now to FIGS. 16-21, an alternate corner condition 178 isdescribed herein. According to various embodiments, the corner adapter150 can include a vertical flange 180 that extends outward from an endwall 44 of the block module 12 that engages the corner condition 178.The vertical flange 180 can extend substantially the entire height ofthe corner adapter 150, the entire full height or greater than the fullheight of the corner adapter 150. Accordingly, the vertical flange 180can be configured to engage two vertically adjacent block modules 12that are within the corner condition 178. It is contemplated that thecorner adapter 150 having a vertical flange 180 is typically disposedproximate the inner corner condition 182, generally where two innerstructural members 14 of adjacent block modules 12 meet at the cornercondition 178. In this manner, a flange receiver 184 can be disposed atthe inner corner condition 182 to receive two vertical flanges 180 thatextend from the inner structural members 14 of the adjacent blockmodules 12. It is contemplated that the flange receiver 184 includes twoflange slots 186, each of which is adapted to receive a separatevertical flange 180 from adjacent wall portions of the modular blocksystem 10.

Referring again to FIGS. 16-21, when two adjacent wall portions arepositioned adjacent one another at a predetermined angle, the cornercondition 178 can be constructed by placing corner adapters 150 withinthe inner structural members 14 of the block modules 12 of the adjacentwall portions. Once the corner adapters 150 having the vertical flanges180 are in position, the flange receiver 184 can be slidably engagedwith the vertical flanges 180 of the adjacent corner adapters 150. Inthis manner, the flange receiver 184 can at least partially secure theadjacent block modules 12 of the two adjoining wall portions. Accordingto various embodiments, the flange receiver 184 can include a pluralityof angular configurations such that flange slots 186 defined withinreceiver walls 188 of the flange receiver 184 can be set at varyingangles to receive the block modules 12 of wall portions that may meet atnon-perpendicular angles. It is also contemplated that the flangereceiver 184 can include more than two flange slots 186 defined withinvarious receiver walls 188 of the flange receiver 184. In this manner,three or more adjacent wall portions that meet at a particular cornercondition 178 can be joined together by the engagement of the flangereceiver 184 and the vertical flanges 180 of the various corner adapters150 that are disposed at the corner condition 178.

As illustrated in the embodiment of FIG. 20, the adjacent wall portionsthat define the corner condition 178 where the flange receiver 184 andthe vertical flange 180 of the corner adapter 150 engage, the end walls44 of each of the block modules 12 are substantially co-planarthroughout the height of the wall portion. Accordingly, a plurality offlange receivers 184 can be stacked vertically upon one another, as thevarious higher courses 110 of the modular block system 10 are assembled.According to various embodiments, it is contemplated that once theadjacent wall portions of the modular block system 10 are complete, asingle flange receiver 184 having substantially the same height as theadjacent wall portions of the corner conditions 178 can be slidablyengaged with each of the vertical flanges 180 of the various corneradapters 150. By sliding the single flange receiver 184 downward and inprogressive slidable engagement with the various vertical flanges 180disposed within the block modules 12. A single flange receiver 184 canengage all of the vertical flanges 180 of the corner condition 178. Itis also contemplated that long sections of the flange receivers 184 thatvertically extend across multiple block modules 12 within the wallportion can be installed to form at least a portion of the cornercondition 178. It is also contemplated that once the one or more flangereceivers 184 are disposed within the corner condition 178 tosubstantially secure the various block modules 12 at the cornercondition 178, a structural member can be inserted through a cavity 190defined by the receiver walls 188 of the flange receiver 184 to provideadditional structural support to the flange receiver 184 when engagingthe various block modules 12 of the modular block system 10. Suchreinforcing members can include, but are not limited to, steel,structural adhesives, epoxy, cement-type materials, wood, combinationsthereof, or other substantially structural material that can be insertedwithin the cavity 190 defined by the one or more flange receivers 184.In various alternate embodiments, it is contemplated that the cavity 190of the flange receiver 184 can be filled with spray foam or otherinsulating material.

Referring again to FIGS. 19-21, while the flange receiver 184 isdisposed at an inner corner condition 182 of the corner condition 178,an outer corner block 156, as substantially described above, can be usedto provide structural support for the outer portion 192 of the cornercondition 178. In this manner, as the outer corner block 156 is disposedat the outer portion 192 of the corner condition 178, corner adapters150 are configured to slidably engage the end walls 44 of the variousblock modules 12 disposed within the adjoining wall portions. Theadapter portion 154 of the corner adapter 150 is then slidably engagedwith the adapter ends 194 of the corner block 156 that include recesseshaving a shape that matingly engages the adapter portions 154 of thecorner adapters 150.

Referring again to FIG. 20, as discussed above, the end walls 44 of thevarious block modules 12 positioned at the ends of the wall portionsthat define the corner condition 178 are substantially vertical. Assuch, because the various block modules 12, as the courses are created,are vertically staggered, half-size block modules 196, orfractional-size block modules are necessary in order to complete thewall portion to form the corner condition 178 that the corner adapters150, flange receivers 184, and corner blocks 156 can be installedwithin. These half-size block modules 196, or partial blocks, can bebuilt in substantially the same manner as that of the full-size blockmodules 12 described above, with the exception that the half-size blockmodules 196, or partial blocks, have a decreased length to account forthe staggered placement of the various block modules 12.

Referring now to FIG. 22, having described the mortarless modular blocksystem 10 and the construction of the individual block modules 12, amethod 400 is disclosed for constructing a wall using an embodiment of amortarless modular block system 10. A first step of the method 400includes providing a plurality of block modules 12 (step 402). Each ofthe plurality of block modules 12 includes inner and outer structuralmembers 14, 16, with each of the inner and outer structural members 14,16 including upper and lower retaining grooves 18, 20. A bottom spanningmember 22 extends the length of the inner and outer structural members14, 16, wherein the second pair of securing members 48 of the bottomspanning member 22 are configured to be retained within the lowerretaining grooves 20 of the inner and outer structural members 14, 16.The bottom spanning member 22 also includes a first retaining feature24. Each of the plurality of block modules 12 also includes a topspanning member 26 that extends the length of the inner and outerstructural members 14, 16. The first pair of securing members 46 of thetop spanning member 26 are configured to be retained within the upperretaining grooves 18 of the inner and outer structural members 14, 16with the top spanning member 26 including a second retaining feature 28that cooperates with a first retaining feature 24 of the bottom spanningmember 22 of an adjacent block module 12. An insulation member 30 isalso disposed within an interior volume of each of the block modules 12that is defined by the inner and outer structural members 14, 16 and thetop and bottom spanning members 26, 22 of each of the block modules 12.As discussed above, the exact construction of each of the block modules12 can vary as discussed in the embodiments described herein.Additionally, each of the block modules 12, or a portion of the blockmodules 12, is intended to be manufactured and assembled off site.However, each block module 12, if necessary, can be constructed on sitedepending upon the exact needs of the construction project.

Referring again to FIG. 22, the method 400 includes the step of placingat least two adjacent block modules 12 upon a foundation 116, or upon alower course 112 of block modules 12 units (step 404). As discussedabove, when a course of block modules 12 is placed upon a foundation116, the block modules 12 can be attached to the wood sill plate of thefoundation 116 via receiving plates 118 that extend upward from thefoundation 116. Alternatively, the block modules 12 of the lower course112 can be disposed upon the wood sill plate of the foundation 116 viasome form of adhesive that can include, but is not limited by, epoxy,silicone, or some other form of adhesive. The lower course 112 of blockmodules 12 can also be attached to the wood sill plate of the foundation116 via various mechanical fasteners that can include, but are notlimited to, ties, straps, bolts, lags, and other various mechanicalfasteners. It is also contemplated that these mechanical fasteners canbe used to attach the receiving plate 118 to a sill plate secured to thefoundation 116.

As illustrated in FIG. 22, once the two adjacent block modules 12 areplaced upon the foundation 116, another step in the method 400 includesaligning the at least two adjacent block modules 12 to be vertically andlaterally aligned within the lower course 112 (step 406). As discussedabove, a higher course 110 of block modules 12 can only be slidablyengaged with the two block modules 12 of the lower course 112 if each ofthe block modules 12 of the lower course 112 is vertically and laterallyaligned. Once properly aligned, the first and second retaining features24, 28 of the block modules 12 of the higher and lower courses 110, 112can slidably engage with one another. In this manner, the mortarlessmodular block system 10 is a self-leveling system that causes properalignment of the various block modules 12 through their slidableengagement with one another. Where block modules 12 are out of verticalor lateral alignment, or both, subsequent courses of block modules 12are prevented from being slidably engaged with the lower course 112,until such time as proper vertical and lateral alignment is achievedbetween the block modules 12 of the lower course 112.

Referring again to FIG. 22, another step in the method 400 includessliding a vertically adjacent block module 12 onto the at least twoblock masonry modules 12 within the lower course 112 that have beenproperly aligned (step 408). The vertically adjacent block module 12defines the location of the higher course 110 on top of the lowercourses 112. In this manner, the first and second retaining features 24,28 of the vertically adjacent block modules 12 slidably engage oneanother such that the block module 12 of the higher course 110 can belocated in relation to the block modules 12 of the lower course 112.Accordingly, when the block module 12 of the higher course 110 ispositioned in relation to the block modules 12 of the lower course 112,the connection between the higher and the lower course 110, 112 createsa secure, structural and self-leveling connection that is free of theuse of mortar. It should be noted that while the system can operatewithout the use of mortar, for aesthetic purposes or for weatherproofingpurposes, certain mortar products can be used in conjunction with themortarless modular block system 10.

Referring again to FIG. 22, another step in the method 400 includesinserting a corresponding expansion member 70 into a respective hollowinterior portion 68 of the first, second, third and fourth securingmembers 60, 62, 64, 66 of the inner and outer structural members 14, 16,respectively. Each corresponding expansion member 70 is inserted througha corresponding securing aperture 42 disposed at ends of each of theexpanding portions. The insertion of the corresponding expansion member70 into each hollow interior portion 68 is configured to expand each ofthe corresponding first, second, third and fourth securing members 60,62, 64, 66. In this manner, as the first, second, third and fourthsecuring members 60, 62, 64, 66 expand due to the insertion of theexpansion member 70, the expansion causes a secure fit between thefirst, second, third and fourth securing members 60, 62, 64, 66 and therespective upper and lower retaining grooves 18, 20 of the inner andouter structural members 14, 16. It is contemplated that step 410 can beperformed in an off-site manufacturing facility and can be performed asa step in manufacturing each block module 12 before delivery to thebuilding site.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

What is claimed is:
 1. A block module for a modular block system, each block module comprising: a structural component having inner and outer portions; and first and second retaining features extending outward from the inner and outer portions of the structural component, the first retaining feature being integrally formed with a first spanning member extending between the inner and outer portions of the structural component, and the second retaining feature being integrally formed with a second spanning member that opposes the first spanning member and extends between the inner and outer portions of the structural component, wherein the first and second spanning members position the inner and outer portions of the structural component at a predetermined spacing, wherein the first retaining feature is configured to slidably engage the second retaining feature of an adjacent block module.
 2. The block module of claim 1, wherein the first and second retaining features are mortar-free retaining features.
 3. The block module of claim 1, wherein the inner and outer portions of the structural component are defined by separate inner and outer structural components.
 4. The block module of claim 1, wherein an insulation member is engaged with the structural component.
 5. The block module of claim 4, wherein the insulation member is disposed between the inner and outer portions of the structural component.
 6. The block module of claim 5, wherein the first and second spanning members exert a laterally inward compressive force against the inner and outer portions of the structural component to compress the insulation member between the inner and outer portions and secure the inner and outer portions, the first and second spanning members and the insulation member in a unitary member to form the block module.
 7. The block module of claim 1, wherein the structural component is masonry.
 8. A block module for a modular block system, each block module comprising: a structural member having upper and lower retaining grooves; a bottom spanning member extending a length of the structural member, wherein the bottom spanning member is configured to be retained within the lower retaining groove of the structural member, and wherein the bottom spanning member includes a first retaining feature; a top spanning member extending the length of the structural member, the top spanning member retained within an upper retaining groove of the structural member, wherein the top spanning member includes a second retaining feature that is configured to matingly and slidably cooperate with the first retaining feature of an adjacent block module to vertically and laterally align the structural member with the adjacent block module; and an insulation member disposed within an interior volume defined between the structural member and the top and bottom spanning members to define a unitary member.
 9. The block module of claim 8, wherein the structural member includes inner and outer structural members, the top and bottom spanning members extending between the upper and lower retaining grooves defined within each of the inner and outer structural members.
 10. The block module of claim 9, wherein the insulation member is disposed between the inner and outer structural members and the top and bottom spanning members.
 11. The block module of claim 9, wherein the top and bottom spanning members are adapted to position the inner and outer structural members at a predetermined distance.
 12. The block module of claim 9, wherein the top and bottom spanning members engage the upper and lower retaining grooves to exert a compressive force against the inner and outer structural members to compress the insulation member between the inner and outer structural members and secure the inner and outer structural members, the top and bottom spanning members and the insulation member in the unitary member.
 13. The block module of claim 8, wherein the insulation member is a solid piece of insulation.
 14. The block module of claim 8, wherein the inner and outer structural members are masonry.
 15. The block module of claim 8, wherein the top and bottom spanning members are made of plastic.
 16. A modular block system comprising: a plurality of block modules, each of the plurality of block modules including: a bottom spanning panel including engagement rails defined respectively within bottom opposing edges of the bottom spanning panel; a top spanning panel having top opposing edges; and an insulation member disposed within an interior volume defined between the top and bottom spanning panels, wherein the engagement rails of a first block module of the plurality of block modules is adapted to slidably engage the top opposing edges of the top spanning panel of at least one vertically adjacent block module of the plurality of block modules, wherein slidable engagement between the first block module and the at least one vertically adjacent block module secures and vertically and laterally aligns the first block module and the at least one vertically adjacent block module substantially free of the use of mortar, and wherein the first block module is unable to slidably engage two block modules of the at least one vertically adjacent block module when the two block modules are free of at least one of vertical and lateral alignment.
 17. The modular block system of claim 16, wherein each block module of the plurality of block modules includes at least one structural member, the top and bottom spanning panels extending from upper and lower retaining grooves, respectively, of the at least one structural member, wherein the at least one structural member and the top and bottom spanning panels cooperate to define the interior volume.
 18. The modular block system of claim 17, wherein the at least one structural member includes inner and outer structural members, wherein the top and bottom spanning panels engage the inner and outer structural members and position the inner structural member a predetermined distance from the outer structural member.
 19. The modular block system of claim 16, wherein the engagement rails of the bottom spanning panel are adapted to receive a second retaining feature of the top spanning panel of the at least one vertically adjacent block module.
 20. The modular block system of claim 16, wherein the top and bottom spanning panels are made of plastic. 